Water resistant protective garment for fire fighters

ABSTRACT

A protective garment of the type typically worn by fire fighters with improved water resistance is disclosed. In particular, the present invention is directed to an outer shell material for protective garments that is made from a fire resistant material coated with a durable water resistant coating. The durable water resistant coating is applied to the outer shell in a manner so that the coating will not degrade when exposed to normal wear and tear and even after the garment has been laundered repeatedly. Protective garments constructed in the past typically lost most of their water repellency after being laundered as little as five cycles. It has been discovered that water resistant coatings applied according to the process of the present invention, on the other hand, can survive at least 30 laundry cycles, and in many applications at least 50 laundry cycles without significantly degrading.

RELATED APPLICATIONS

This application is a continuation of U.S. Ser. No. 09/925,014 filed onAug. 8, 2001 now U.S. Pat. No. 6,606,749, which is a continuation ofU.S. Ser. No. 09/734,374 filed on Dec. 11, 2000 and now abandoned, whichis a continuation of U.S. Ser. No. 09/188,635 filed on Nov. 9, 1998 andnow issued as U.S. Pat. No. 6,192,520, which is a continuation-in-partof U.S. Ser. No. 09/016,097 filed Jan. 30, 1998, and now issued as U.S.Pat. No. 6,065,153.

FIELD OF THE INVENTION

The present invention generally relates to protective garments such asthe type worn by fire fighters. More particularly, the present inventionis directed to a protective garment having a water resistant outershell. In particular, an outer shell made according to the presentinvention has proven to be able to retain its primary water resistantproperties even after undergoing 30 laundry cycles.

BACKGROUND OF THE INVENTION

Protective garments worn by fire fighters are designed to performseveral functions. Of these, protection from heat and flame are perhapsthe most important characteristics of the garments. In addition toproviding protection from heat and flame, the garments, however, shouldbe as light as possible, should provide some breathability and shouldencumber the wearer as little as possible.

Conventional fire fighter garments are generally constructed having anumber of discrete layers. Typically, these layers include an outershell, a moisture barrier layer, a thermal barrier layer, and an innerlining. The layers are generally made from appropriatethermally-resistant materials to provide protection against heat andflame.

In the past, one difficulty that has been encountered in designingprotective garments to be worn by fire fighters is to prevent thegarments from absorbing and retaining moisture. For instance, protectivegarments worn by fire fighters usually become wet during use due toexternal exposure to extinguishing water or rain. Also, fire fightergarments can become wet due to the absorption of perspiration given offby the wearer. Unfortunately, when the protective garment absorbsmoisture, the characteristics and properties of the garment can beadversely affected. For example, when retaining moisture, the protectivegarment can become significantly heavier.

Besides increasing in weight, the presence of moisture within aprotective garment also adversely affects the thermal properties of thegarment making the garment less effective in shielding its wearer fromthermal heat. In particular, since water is a much better heat conductorthan air, the rate of heat transfer through the garment increases. Also,it has been discovered that as water heats up in a protective garment,the water can turn to steam under exposure to heat and actually burn aperson wearing the garment.

Ultimately, when protective garments as described above become wet orsoaked with water or other fluids, the garments become hot anduncomfortable to work in due to the increased weight and due to theincreased rate of heat transfer through the garment. As a consequence, awearer can only spend a limited amount of time working or performingtasks in the garment due to the possibility of heat stress.

In the past, in order to prevent water from being absorbed by protectivegarments worn by firemen, the garments have been treated with a waterresistant composition. The water resistant treatments applied toconventionally made protective garments, however, have not proven to bedurable and have been found to become ineffective after the garment hasbeen placed in use for a period of time. In particular, it has beendiscovered that conventionally applied water resistant treatments becomesignificantly degraded when the protective garment is washed.Specifically, it has been found that the water resistant treatmentsbegin to degrade only after five (5) laundry cycles and typically losemost of their effectiveness after ten (10) laundry cycles.

As such, a need currently exists for an improved water resistant fabricand protective garment to be worn by fire fighters. More particularly, aneed exists for a method of applying a water resistant treatment to aprotective garment that will not degrade over a period of time and thatcan withstand normal laundering.

SUMMARY OF THE INVENTION

The present invention recognizes and addresses the foregoingdisadvantages, and others of prior art constructions and methods.

Accordingly, an object of the present invention is to provide animproved protective garment suitable for use by a fire fighter.

It is another object of the present invention is to provide a protectivefabric for making garments that has been treated with a durable waterresistant treatment.

Still another object of the present invention is to provide a protectivefabric having a water resistant treatment that can withstand normallaundering.

It is another object of the present invention to provide a protectivegarment for fire fighters that contains a durable water resistanttreatment applied to an exterior shell that allows the garment tomaintain a spray rating of at least 70 even after 30 laundry cycles.

These and other objects of the present invention are achieved byproviding a fabric for constructing a protective garment suitable foruse by a fire fighter. The protective garment includes an inner liningconfigured to cover a predetermined portion of a wearer's body. Theinner lining is positioned so as to be placed adjacent to the wearer'sbody during use. An outer shell made from the above fabric covers theinner lining and is made from a fire resistant material.

In accordance with the present invention, a durable water resistanttreatment is incorporated into the outer shell. The durable waterresistant treatment is affixed to the outer shell such that the outershell maintains a spray rating of at least 70 even after 30 laundrycycles, and, in some applications, maintains a spray rating of at least70 even after 50 laundry cycles. In an alternative preferred embodimentof the present invention, the outer shell is constructed so as tomaintain a spray rating of at least 80 after 20 laundry cycles.

Besides maintaining a high spray rating, an outer shell constructed inaccordance with the present invention also maintains very good waterabsorption ratings and dynamic water absorption ratings after beinglaundered. For instance, after five laundry cycles, the outer shell hasbeen found to maintain a water absorption rating of less than about 8%,particularly less than about 6%, and in a preferred embodiment less thanabout 4%. The outer shell can have a dynamic water absorption rating ofless than about 15% after ten laundry cycles, particularly less thanabout 12% after ten laundry cycles, and more particularly less thanabout 10% after ten laundry cycles. After twenty laundry cycles, theouter shell maintains a dynamic water absorption rating of less thanabout 18%, more particularly less about 15%, and preferably less thanabout 12%.

In one embodiment, the outer shell can be made from a woven fabric, suchas having a plain, twill or rip stop weave. The material used to makethe outer shell can be an aramid polymer or can be a mixture of anaramid polymer and polybenzimidazole. The woven fabric used to make theouter shell can have a weight of from about 5.5 ounces per square yardto about 8 ounces per square yard, and particularly at a weight of about7.5 ounces per square yard. Further, a thermal barrier layer can bepositioned between the outer shell and the inner lining.

The durable water resistant treatment applied to the outer shell cancontain a fluorocarbon polymer. The water resistant treatment can beapplied to the outer shell as a solution and then later cured or driedby heating the outer shell fabric.

These and other objects of the present invention are also achieved byproviding a process for producing a water resistant fabric particularlywell adapted for use as an exterior covering for a fire fightersprotective garment. The process includes the steps of providing a fireresistant material. For instance, the fire resistant material can be awoven fabric made from a fire resistant polymer, such as an aramidpolymer. In one embodiment, the fire resistant material is scoured, suchas by being exposed to an alkaline solution. After scouring, thematerial is dried.

Once dried, a durable water resistant treatment, such as a fluorocarbonpolymer solution, is then applied to at least one side of the fireresistant material. Once the water resistant treatment is applied to thematerial, the material is heated until the treatment is dried and cured.In particular, according to the present invention, the durable waterresistant treatment is affixed to the fire resistant material such thatthe material maintains a spray rating of at least 70 even after 30laundry cycles.

Other objects, features and aspects of the present invention arediscussed in greater detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including thebest mode thereof, to one of ordinary skill in the art, is set forthmore particularly in the remainder of the specification, includingreference to the accompanying figures, in which:

FIG. 1 is a perspective view of one embodiment of a protective garmentmade according to the present invention;

FIG. 2 is a cross-sectional view of the garment illustrated in FIG. 1;and

FIGS. 3A-3F are diagrammatical views of illustrative examples of sprayratings for a standardized fabric spray test.

Repeat use of reference characters in the present specification anddrawings is intended to represent same or analogous features or elementsof the invention.

DEFINITIONS AND STANDARDIZED PROCEDURES

The following definitions and procedures are offered in order to betterdescribe and quantify the performance of protective garments and fabricsmade according to the present invention in comparison to prior artconstructions.

Spray Test

As used herein, a fabric spray rating refers to a rating a fabric or amaterial receives according to AATCC SPRAY TEST METHOD 22-1996. Ingeneral, a spray test measures the resistance of a material to wettingby water.

According to the present invention, the following is the procedure usedto determine the spray rating of a material.

1. An 7″×7″ sample of the material to be tested is first conditioned at65 plus or minus 2% relative humidity and at 70 plus or minus 2° F. fora minimum of four hours prior to testing.

2. The fabric sample is fastened securely on a 6″ metal hoop so that thefabric is wrinkle free. The hoop is supported on a tester's stand sothat the fabric is facing up. Twills, gabardines, piques or similarfabrics of ribbed construction are positioned on the stand so that theribs are diagonal to the flow of water running off the fabric. A funnelattached to a nozzle for holding water is placed 6″ above the center ofthe fabric.

3. 250 milliliters of water at 80 plus or minus 2° F. are poured from acup or other container into the funnel, allowing the water to spray ontothe fabric.

4. Once the water has run through the funnel, one edge of the hoop isheld and the opposite edge is firmly rapped once against a solid objectwith the fabric facing the object. The hoop is then rotated 180° and itis rapped once more at the point previously held.

5. The wetted or spotted fabric sample is then compared with thestandards shown in FIGS. 3A-3F. The fabric is assigned a spray ratingthat corresponds to the nearest standard. As shown on FIGS. 3A-3F, thefabric can be rated from 0 to 100 wherein 0 indicates that the entirefabric is wetted with the water, while a rating of 100 indicates thatnone of the fabric was wetted by the water.

Water Repellency Test

The following standardized water repellency test determines a material'sresistance to wetting by aqueous liquids. In general, drops of awater-alcohol mixture of varying surface tensions are placed on thesurface of the material and the extent of surface wetting is determinedvisually. The higher the rating a material receives is an indication ofthe material's resistance to staining by water-based substances. Thecomposition of standard test liquids is as follows:

TABLE 1 Standard Test Liquids Water Repellency Composition Rating NumberIsopropanol, % Distilled Water, % 1 2 98 2 5 95 3 10 90 4 20 80 5 30 706 40 60 7 50 50 8 60 40

The water repellency procedure is as follows:

1. A 2″×8″ sample of material is first conditioned at 65 plus or minus2% relative humidity and at 70 plus or minus 2° F. for a minimum of fourhours. The fabric is placed horizontally face up on white blottingpaper.

2. Beginning with test liquid number 1, one drop of the liquid is placedat three locations on the material. Each drop placed on the materialshould be 2″ apart.

3. The material is observed for 10 seconds from an approximate 45°angle.

4. If two of the three drops have not wet the fabric or do not showleaking into the fabric, drops of test liquid number 2 are placed on anadjacent site and step number 3 is repeated.

5. This procedure is continued until 2 of the 3 drops have wet or showwicking into the fabric. The water repellency rating is the highestnumbered liquid for which 2 of the three drops do not wet or wick intothe fabric.

Oil Repellency Test

The following oil repellency test determines how well finished fabricsresist oily stains and wetting by organic liquids. In this test, dropsof eight liquid hydrocarbons of various surface tensions are placed onthe surface of the material and the extent of surface wetting isdetermined visually. The standard test liquids used are as follows:

TABLE 2 Oil Repellency Standard Test Liquids Hydrocarbon Rating NumberRefined Mineral Oil 1 Refined Mineral 2 Oil/n-Hexadecane 65/35% byvolume at 21° C. n-Hexadecane 3 n-Tetradecane 4 n-Dodecane 5 n-Decane 6n-Octane 7 n-Heptane 8

1. A 2″×8″ sample of material is conditioned at 65 plus or minus 2%relative humidity and at 70 plus or minus 2° F. for a minimum of fourhours before testing. The fabric is placed in a horizontal position faceup on white blotting paper.

2. Beginning with liquid number 1, drops approximately 5 milliliters indiameter or 0.05 microliters in volume are placed on the test sample inseveral locations.

3. The drops are observed for 30 seconds from an approximate 450 angle.Wetting of the fabric is normally shown by darkening at theliquid/fabric interface. On black or dark fabrics, wetting can bedetected by a loss of sparkle within the drop.

4. If liquid number 1 does not penetrate or wet the fabric or showwicking around the drops, drops of liquid number 2 are placed onadjacent portions of the fabric and observed for 30 seconds.

5. This procedure is continued until the fabric shows wetting under oraround the drops of test liquid within 30 seconds. A sample's AATCC oilrepellency rating is the number of the highest numbered test liquid thatwill not wet the fabric or show wicking within 30 seconds.

Laundering Test

Laundering is preferably performed in a KENMORE automatic washer,followed by drying in a KENMORE automatic dryer. The followinglaundering test is used to determine the fabric's ability to withstandlaundering. Typically, after laundering, the fabric is then subjected tothe above-described spray test, water repellency test, and oilrepellency test.

1. 8″×10″ test specimens are combined with load fabrics (hemmed piecesof cotton sheeting or 50:50 fabric sheets having a size of 36″×36″) togive a total dry load of 4 pounds.

2. The dials on the washer are set as follows:

Water Level High Wash Cycle Normal, 12 minutes Temperature Warm Wash,105° F.; Cold RinseThe test pieces and dummy load are placed in the washer and the machineis started. One ounce of TIDE (Proctor & Gamble) detergent is addedwhile the washer is filling with soft water. If the water hardness isgreater than 5 ppm, CALGON water softener (Nalco) in the amountspecified by the manufacturer is added to soften the water.

3. After the washing is complete, the wet fabric including the dummyload is placed in the automatic dryer. The dryer temperature dial is setto the proper point under high heat to give a maximum vent temperatureof from about 155° F. to about 160° F. The time dial is set for “NormalCycle” for 45 minutes. The machine is started and drying is allowed tocontinue until the cycle is complete. The above represents one laundrycycle.

4. The fabrics are then rewashed and redried until 10 cycles have beencompleted. Optionally, the test fabrics can be pressed with a hand iron,or the equivalent, at 280° F. to about 320° F. for 30 seconds on eachside with the face side pressed last. The fabrics are then conditionedbefore testing for water repellency, oil repellency, or spray rating. Asused herein, water repellency, oil repellency and spray ratings are alldetermined without ironing the fabric after being laundered, unlessotherwise denoted.

Water Absorption Test

The following water absorption test is for determining the resistance towater absorption of a fabric or material. The test is based upon NFPA1971, 6-26. In particular, the water absorption test is conductedaccording to the above-identified test method after the fabric ormaterial has been subjected to five laundry cycles in accordance withNFPA 1971, 6-1.2.

According to the present invention, the following is the procedure usedto determine the water absorption rating of a material.

1. Three 8″×8″ samples of the material to be tested are subjected tofive laundry cycles in accordance with NFPA 1971, 6-1.2. Test methodNFPA 1972, 6-1.2 is substantially similar to the laundering testdescribed above. In this test, however, the specimens are conditioned inan atmosphere of 70 plus or minus 2° F. and 65 plus or minus 2% relativehumidity before and after being washed. Further, the machine settingsand parameters are as follows:

water level normal wash cycle normal/cotton sturdy wash temperature140 + or −5° F. drying cycle tumble/cotton sturdy detergent 66 + or −1 gof 1993 AATCC standard Reference Detergent

2. Each sample is securely mounted, with the coated side of the materialup, to embroidery hoops with sufficient tension to ensure a uniformlysmooth surface. The hoop is supported on a tester's stand. The materialis positioned so that the direction of the flow of water down the sampleshall coincide with the warpwise direction of the sample as placed onthe stand. A funnel attached to a nozzle for holding water is placed 24″above the center of the material. The plane of the surface of the sampleis placed at a 45° angle with the horizontal.

3. 500 ml of water at a temperature of 80 + or − 2° F. are pouredquickly into the funnel and allowed to spray onto the specimen.

4. As rapidly as possible, the sample is removed from the hoops andplaced between two sheets of blotting paper on a flat horizontalsurface. A metal roller approximately 4½″ long and weighing 2¼ pounds isrolled quickly forward and back one time over the paper withoutapplication of any pressure other than the weight of the roller.

5. A square having dimensions of 4″×4″ is cut out of the center of thesample and weighed to the nearest 0.05 grams. Not more than 30 secondsshall elapse between the time the water has ceased flowing through thespray nozzle and the start of the weighing.

6. The same 4″×4″ square sample is then left in a conditioning roomuntil it has dried and reached moisture equilibrium with the surroundingatmosphere. The sample is then weighed again.

7. The water absorbed shall be calculated as follows:${{water}\quad{absorbtion}},{{percent} = {\frac{W - O}{O} \times 100}}$herein W is the weight of the wet sample and O is the weight of thedried sample. The water absorption rating of the sample is the averageof the results obtained from the three specimens tested.Dynamic Water Absorption Test

The following test also measures the resistance of materials to wettingby water. It is particularly suitable for measuring the water-repellentefficacy of finishes applied to fabrics, because the test subjects thetreated fabrics to dynamic conditions similar to those often encounteredduring actual use. The test conforms to AATCC Test Method No. 70-1997.

According to the present invention, the following is the procedure usedto determine the dynamic water absorption rating of a material.

1. During the test, two specimen sets are tested. Each specimen setconsists of five 8″×8″ pieces of the material. For each piece that iscut, the corner yarns are removed and, if necessary, a drop of liquidlatex or rubber cement is placed at the corners to prevent raveling.Prior to testing, each piece of material is conditioned at 65 + or − 2%relative humidity and at 70 + or − 2° F. for a minimum of four hours.Blotting paper to be used later is also conditioned.

2. The five pieces of each specimen set are rolled together and weighedto the nearest 0.1 gram.

3. Two liters of distilled water at 80 + or − 2° F. is poured into thetumble jar of a dynamic absorption tester. The dynamic absorption testershould consist of a motor driven, 6 liter cylindrical orhexagonal-shaped jar approximately 6″ in diameter and 12″ in length,mounted to rotate end over end at 55+ or − 2 rpm with a constanttangential velocity. The jar may be of glass, corrosion resistant metal,or chemical stoneware.

4. Both specimen sets are placed into the jar and the jar is rotated inthe tester for 20 minutes.

5. A piece of one specimen set is then immediately passed through aringer at a rate of 1″ per second with the edge of the piece parallel tothe rolls. The piece is sandwiched between two pieces of unused blotterpaper and passed through the ringer again. The piece is left sandwichedbetween the wet blotters. The process is then repeated for the remainingfour pieces of the specimen set. The blotters are removed and the fivepieces are rolled together, put in a tared plastic container orgallon-sized zippered plastic bag and the wet specimen set is weighed tothe nearest 0.1 gram. The mass of the wet specimen set should not bemore than twice its dry mass.

6. Step number five is repeated for the second specimen set.

7. The dynamic water absorption for each specimen set is calculated tothe nearest 0.1% using the following equation:WA=(W−C)/C×100where

-   -   WA=water absorbed, percent    -   W=wet specimen weight, g    -   C=conditioned specimen weight, g.

8. The dynamic water absorption of the material is determined byaveraging together the water absorbed by each of the two specimen sets.

9. According to the present invention, the dynamic water absorptionrating of the material can be determined after laundering the samples inaccordance with NFPA 1971, 6-1.2. For instance, the samples can betested after 10 laundry cycles and after 20 laundry cycles to determinethe durability of the water resistant coating.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

It is to be understood by one of ordinary skill in the art that thepresent discussion is a description of exemplary embodiments only, andis not intended as limiting the broader aspects of the presentinvention, which broader aspects are embodied in the exemplaryconstruction.

In general, the present invention is directed to a fabric and aprotective garment for fire fighters that has improved water resistantproperties. In particular, the present invention is directed to a firefighters garment having an outer shell fabric that has been treated witha durable water resistant composition. The water resistant treatmentprevents water and moisture from being absorbed by the garment. Incomparison to prior art constructions, the water resistant treatment asapplied according to the process of the present invention is much moredurable in that the treatment will not significantly degrade or wear offthe garment when exposed to normal wear and tear. In particular, it hasbeen discovered that water resistant treatments applied according to thepresent invention can withstand at least 30 laundry cycles withoutlosing a substantial amount of effectiveness.

Referring to FIG. 1, one embodiment of an improved protective garmentgenerally 10 constructed in accordance with the present invention isillustrated. Garment 10 includes a relatively tough outer shell 12having a liner assembly 14 located therein. Outer shell 12 and linerassembly 14 together function to protect a wearer from heat and flamesuch as may be encountered during fire fighting activities.

In the illustrated embodiment, liner assembly 14 is constructed as aseparate unit that may be removed from outer shell 12. A zipper 16 isprovided for removably securing liner assembly 14 to outer shell 12. Itshould be appreciated, however, that other suitable means of attachment,including a more permanent type of attachment such as stitches, may alsobe used between liner assembly 14 and outer shell 12.

The construction of protective garment 10 is more particularlyillustrated in FIG. 2. As shown, liner assembly 14 includes a pluralityof material layers quilted together. The outermost layers, i.e. lininglayers 20 and 22, are connected together about their respectiveperipheries to form an inner cavity. A thermal barrier layer 24 and amoisture barrier layer 26 are located within the inner cavity, as shown.Typically, lining layer 20 will be adjacent the wearers body during use,whereas lining layer 22 will be adjacent outer shell 12.

Thermal barrier layer 24, can be made from various materials. Forinstance, an aramid felt, such as a felt produced from NOMEX fibersobtained from DuPont can be used. The felt functions as an insulator toinhibit transfer of heat from the ambient environment to the wearer.

Moisture barrier 26 is preferably a suitable polymeric membrane that isimpermeable to liquid water but is permeable to water vapor. Moisturebarrier layer 26 is designed to prevent water contacting the exteriorsurface of garment 10 from reaching the wearer while at the same timepermitting the escape of perspiration from the wearer.

Outer shell 12, which can be positioned loosely adjacent to linerassembly 14, includes a woven fabric 28 treated with a durable waterresistant composition 30 in accordance with the present invention. Ingeneral, woven fabric 28 should be made from a mechanical resistant,flame resistant, and thermal resistant material. For instance, wovenfabric 28 can be made from aromatic polyamide polymers, such as aramidfibers. For example, KEVLAR para-aramid fibers, NOMEX meta-aramidfibers, and mixtures of KEVLAR fibers and NOMEX fibers commerciallyavailable from DuPont are particularly well suited for use inconstructing woven fabric 28. Besides KEVLAR fibers and NOMEX fibers,other fibers that may be used to produce the woven fabric includemelamine fibers, such as BASOFIL fibers commercially available fromBASF, poly(p-phenylene-2,6-bezobisoxazole) (PBO) fibers commerciallyavaliable as ZYLON fibers from Toyobo Co., Ltd. or P-84 aramid fibersalso available from Lenzing. It should be understood, however, that anysuitable fire resistant fiber may be used to construct the fabric of thepresent invention.

In one embodiment, the yarns used to make woven fabric 28 can be madefrom a mixture of aramid polymer fibers, such as KEVLAR or NOMEX fibers,and polybenzimidazole (PBI) fibers. In one preferred embodiment of thepresent invention, woven fabric 28 is made from a 60/40 blend of KEVLARpara-aramid fibers and PBI fibers.

The yarns used to produce woven fabric 28 can be assembled in variousdifferent constructions and is generally not critical. For instance,woven fabric 28 can have a twill weave, a plain weave or any othersuitable type of weave. In one preferred embodiment, woven fabric 28 hasa rip stop weave. In general, fabrics having a tighter weave willgenerally have better spray ratings.

The weight of woven fabric 28 generally can vary from about 5.5 ouncesper square yard to about 8 ounces per square yard. Preferably, theweight of woven fabric is from about 6 ounces per square yard to about7.5 ounces per square yard.

In accordance with the present invention, as shown in FIG. 2, wovenfabric 28 is treated with a durable water resistant composition 30. Whenapplied according to the process of the present invention, it has beendiscovered that water resistant treatment 30 is much more durable thanmany prior art constructions. Thus, garments made according to thepresent invention can be routinely laundered and used for an extendedperiod of time without losing their ability to repel water. As describedabove, should a protective garment absorb water, the garment becomesmuch heavier and the thermal properties of the garment become adverselyaffected.

Besides making protective garment 10 impermeable to water, durable waterresistant treatment 30 is also preferably resistant to oil and organicsolvents, is not flammable, and is abrasion resistant. In one preferredembodiment of the present invention, durable water resistant treatment30 is made from a solution containing a fluorocarbon polymer that isapplied to woven fabric 28. For example, durable water resistantcomposition 30 can be made from TEFLON polymers which are commerciallyavailable from DuPont. Fluorocarbon polymer solutions containing TEFLONpolymers are commercially available from numerous sources.

In order to produce a liquid resistant fabric in accordance with thepresent invention, first, a woven fabric is constructed or obtained thatis suitable for use as an outer shell material in a protective garmentfor fire fighters. As described above, the fabric should be made fromflame resistant polymers or other suitable materials.

Prior to applying a durable water resistant treatment, the fabric can befirst scoured, although scouring may not be necessary for allapplications. When scoured, the material can be scoured with an alkalinesolution.

After being scoured, the fabric is then put on a tenter frame, dried andheat set. Specifically, it has been discovered by the present inventorsthat it is important that the fabric be substantially dry and free ofmoisture prior to being treated with the durable water resistantcomposition. For instance, after scouring, the fabric should be dried sothat the moisture level is substantially equivalent to the naturalmoisture level of the fibers used to make the fabric. For instance, formost fibers, the moisture level should be less than about 10%, andparticularly less than about 7%.

After the fabric has been dried and heat set, a durable water resistantcomposition according to the present invention is applied to at leastone side of the fabric. Although the composition can be sprayed on thefabric or printed on the fabric, preferably the fabric is dipped into abath containing the durable water resistant treatment in solution form.

As stated above, the durable water resistant composition, in oneembodiment, can be a solution containing a fluorocarbon polymer. Thefluorocarbon polymer can be combined in the solution with water, adrying agent such as an alcohol, and an emulsifier. The amount of thewater-resistant composition applied to the fabric will depend upon theparticular formulation and the particular application.

After the durable water resistant treatment is applied to the fabric,the fabric is then heated to a temperature sufficient for the coating todry and/or cure. Once the durable water resistant treatment is cured andaffixed to the woven fabric, the fabric can then be used in constructingprotective garments in accordance with the present invention.

It has been discovered that the above-described process securely affixesthe water resistant treatment to the fabric such that the treatmentbecomes much more durable than prior art constructions.

By applying water resistant treatments according to the process of thepresent invention, it has been discovered that the treatments canwithstand numerous laundry cycles. For example, in one embodiment, theouter garment of the present invention has shown to exhibit a sprayrating of at least 80 after 20 laundry cycles. More particularly, evenafter 30 laundry cycles it has been discovered that fabrics madeaccording to the present invention have a spray rating of at least 70and in some applications at least 80, illustrating that the waterresistant treatment does not degrade and does not lose itseffectiveness. Further, after undergoing thirty (30) laundry cycles,fabrics made according to the present invention have also been found toretain a water repellency rating of at least 4 and an oil repellencyrating of at least 3.

Outer garments made according to the present invention have alsodemonstrated superior water absorption and dynamic water absorptionratings. For instance, garments made according to the present inventioncan have a water absorption rating of less than about 8% after fivelaundry cycles, particularly less than about 6% after five laundrycycles and more particularly less than about 4% after five laundrycycles. After ten laundry cycles, garments made according to the presentinvention can have a dynamic water absorption rating of less than about15%, particularly less than about 12%, and preferably less than about10%. The dynamic water absorption rating of garments made according tothe present invention after twenty laundry cycles, on the other hand, ispreferably less than about 18%, particularly less than about 15%, andmore particularly less than about 12%.

The present invention may be better understood with reference to thefollowing examples.

EXAMPLE NO. 1

The following tests were performed in order to demonstrate thesuperiority in performance of fabrics made according to the presentinvention in comparison to conventionally made fabrics.

A woven fabric suitable for use as an outer shell material for a firefighter's protective garment was coated with a durable water resistantcomposition according to the above-described process of the presentinvention. Specifically, the fabric that was treated had the followingcharacteristics and properties:

Material: 60%/40% intimate blend of KEVLAR aramid polymer fibers and PBIfibers Denier: 1.5 Count: 44 yarns/inch Pick: 39 yarns/inch Weave: Ripstop Weight: 7.5 oz/sq. yard

After the above material was scoured, dried and heat set, a durablewater resistant composition was applied to the fabric. The durable waterresistant composition was an aqueous solution containing a fluorocarbonpolymer, an emulsifier, and an alcohol.

The above-treated fabric was then tested for water repellency, oilrepellency, and spray tested initially and after 10, 20, 30, 40 and 50laundry cycles. All the tests were conducted according to theabove-described procedures. The sample was tested both before and afterbeing pressed with a hand held iron. The following results wereobtained:

TABLE 3 Water Repellency, Oil Repellency and Spray Test Results of theFabric Made According to the Present Invention Before Pressing AfterPressing Launderings Water Oil Spray Water Oil Spray Initial 6 5 100 — —— 10 6 5 80 6 5 80 20 6 5 70 6 5 80 30 4-5 3-4 70 6 4 70-80 40 4-5 3-470 6 4 70-80 50 4-5 3-4 70 6 4 70

Commercially available fabrics designed to be used as outer shellmaterials for protective garments were also similarly tested after 10and 30 laundry cycles. Of particular importance, the commercial fabricstested had similar weave characteristics to the above-described fabric.Specifically, one of the products tested was NATURAL PBI obtained fromSouthern Mills and the other fabric tested was PBI SOFT HAND obtainedfrom Dominion Industrial Textiles. The following results were obtained:

TABLE 4 Water Repellency, Oil Repellency, and Spray Test Results ofNATURAL PBI Fabric Obtained from Southern Mills Before Pressing AfterPressing Launderings Water Oil Spray Water Oil Spray Initial 6 5 100 — —— 10 3 0 50 4 0 50 30 2 0 0 2 0 50

TABLE 5 Water Repellency, Oil Repellency, and Spray Test Results of PBISOFT HAND Fabric Obtained from Dominion Industrial Textiles BeforePressing After Pressing Launderings Water Oil Spray Water Oil SprayInitial 6 5 100 — — — 10 1-2 0 50 3 0 50 30 0 0 0 0 0  0

As shown above, the current commercially available fabrics lost half oftheir water resistancy only after 10 laundry cycles. After 30 laundrycycles, the fabrics completely lost their water repellency.

In comparison, the fabric made according to the present inventionmaintained a spray rating of at least 70 after 30 laundry cycles andeven after 50 laundry cycles. As shown above, the fabric made accordingto the process of the present invention also had much better waterrepellency ratings and oil repellency ratings after being laundered. Itis not believed that prior to the present invention an outer shellmaterial was made that contained a water resistant treatment that couldmaintain a spray rating of at least 70 after 30 laundry cycles.

EXAMPLE NO. 2

A woven fabric similar to the one described in Example No. 1 above wascoated with a water resistant composition as described in Example 1. Inthis example, however, the composition applied to the fabric did notcontain an emulsifier but contained more fluorocarbon polymer.

The treated fabric was tested for water repellency, oil repellency andspray tested initially and after 10, 20 and 30 laundry cycles. All thetests were conducted according to the procedures described above. Asample was tested both before and after being pressed with a hand heldiron. The following results were obtained:

TABLE 6 Water Repellency, Oil Repellency and Spray Test Results of aFabric Made According to the Present Invention Before Pressing AfterPressing Launderings water oil spray water oil spray Initial 6 6 100  —— — 10 6 5 90 6 5 100 20 6 5 80-90 6 6 100 30 5-6 4-5 80 6 5 100

As shown above, the treated fabric produced according to this exampleperformed exceptionally well. In particular, the fabric had a sprayrating of at least 80 after 20 laundry cycles, and a spray rating of 80even after 30 laundry cycles. Further, the fabric was found well suitedto repelling water and oil, having a water repellency rating of at least5 and an oil repellency rating of at least 4 after 30 laundry cycles.Even better results were obtained after pressing.

EXAMPLE NO. 3

The following tests were performed in order to compare the performanceof a fabric made according to the present invention in comparison tocommercially available fabrics with respect to water absorption.

A woven fabric similar to the one described in Example No. 1 above wascoated with a water resistant composition as described in Example No. 1.The composition contained a fluorocarbon polymer, isopropanol, aceticacid and water. The flurocarbon polymer used was a dispersion ofperfluroalkyl and polyisocyanate polymers.

The treated fabric was tested for water absorbtion initially and afterfive laundry cycles. All the tests were conducted according to theprocedures described above.

Besides a fabric made in accordance with the present invention,commercially avaliable fabrics were also tested. Specifically, thecommercially avaliable fabrics tested included STANDARD PBI GOLDobtained from Southern Mills, NOMEX OMEGA obtained from SpringsIndustries, and ADVANCE fabric also obtained from Southern Mills. Thefollowing results were obtained:

TABLE 7 Water Absorption Results Initial Water After Five AbsorbtionLaundry Cycles Sample Rating (%) (%) No. 1 0.55 2.09 STANDARD PBI 0.779.84 GOLD NOMEX OMEGA 1.01 16.59 ADVANCE 0.49 12.69

As shown above, the treated fabric produced according to the presentinvention (designated Sample No. 1 above) outperformed the commerciallyavaliable fabrics. In particular, the results above indicate thatfabrics made according to the present invention have water absorptioncharacteristics that are more durable than the commerically avaliableproducts.

EXAMPLE NO. 4

The following tests were performed in order to compare the dynamic waterabsorption characteristics of a fabric made according to the presentinvention in comparison to commercially avaliable fabrics.

The treated fabric described in Example No. 3 above was tested fordynamic water absorption according to the tests described in thespecification. Specifically, the sample was tested initially, after tenlaundry cycles, and after twenty laundry cycles. STANDARD PBI GOLDfabric and ADVANCE fabric obtained from Southern Mills were also tested.The following results were obtained:

TABLE 8 Dynamic Water Absorption Results Initial After Dynamic TwentyWater After Ten Laundry Absorption Laundry Cycles Sample Rating (%)Cycles (%) (%) No. 1 8.3 7.0 10.5 STANDARD 10.8 22.8 37.1 PBI GOLDADVANCE 6.8 20.8 22.1

As shown above, the sample made according to the present invention(designated Sample No. 1 above) had better dynamic water absorptioncharacteristics than the commercially avaliable fabrics.

EXAMPLE NO. 5

The woven treated fabric described in Example No. 3 was once againtested for water absorption. In this example, two other fabrics werecoated as described in Example No. 3 and also tested. The other twofabrics coated according to the present invention had the followingcharacteristics:

Sample No. 2 Material: 60%/40% intimate blend of KEVLAR aramid polymerfibers and PBI fibers Count: 59 yarns/inch Pick: 46 yarns/inch Weave:Rip stop Weight: 7.4 oz/sg. yard Sample No. 3 Material: NOMEXZ-200/OMEGA aramid polymer fibers Count: 41 yarns/inch Pick: 39yarns/inch Weave: Rip stop Weight: 7.75 oz/sq. yard

Sample No. 3 above is a commercially available fabric marketed under thename OMEGA by Springs Industries.

Besides testing the above treated fabrics for water absorption, variouscommerically avaliable fabrics were also similarly tested. Inparticular, OMEGA fabric without being treated in accordance with thepresent invention was tested for water absorption along with STANDARDPBI GOLD fabric, TAN ADVANCE fabric, BLACK ADVANCE fabric, and TAN NOMEXfabric, all obtained from Southern Mills. The following results wereobtained:

TABLE 9 Water Absorption Results Initial Water After Five AbsorptionLaundry Cycles Sample Rating (%) (%) No. 1 0.55 2.07 No. 2 2.07 2.52 No.3 1.53 2.38 OMEGA (untreated) 1.01 16.59 STANDARD PBI GOLD 0.77 9.84 TANADVANCE 0.49 12.69 BLACK ADVANCE 0.84 47.40 TAN NOMEX 1.37 16.94

As shown above, all of the fabrics made according to the presentinvention outperformed the other commercially avaliable fabrics.

These and other modifications and variations to the present inventionmay be practiced by those of ordinary skill in the art, withoutdeparting from the spirit and scope of the present invention, which ismore particularly set forth in the appended claims. In addition, itshould be understood that aspects of the various embodiments may beinterchanged both in whole or in part. Furthermore, those of ordinaryskill in the art will appreciate that the foregoing description is byway of example only, and is not intended to limit the invention sofurther described in such appended claims.

1. A protective garment suitable for use by fire fighters, saidprotective garment comprising: an inner lining assembly configured tocover a predetermined portion of a wearer's body, the inner liningassembly being positioned so as to be adjacent said wearer's body duringuse, the inner lining assembly comprising a thermal barrier layer and amoisture barrier layer positioned in between a first lining layer and asecond lining layer; an outer shell covering said inner lining assembly,the outer shell comprising a woven fabric made from a fire resistantmaterial, the woven fabric having a basis weight of at least about 5.5ounces per square yard; and a durable water resistant compositionincorporated into the woven fabric, the durable water resistantcomposition being incorporated into the woven fabric such that the outershell has a water absorption rating of less than about 8% after beinglaundered five laundry cycles.
 2. A protective garment as defined inclaim 1, wherein the outer shell has a basis weight of about 6 ouncesper square yard or less.
 3. A protective garment as defined in claim 1,wherein the outer shell has a water absorption rating of less than about6% after five laundry cycles.
 4. A protective garment as defined inclaim 1, wherein the outer shell has a water absorption rating of lessthan about 4% after five laundry cycles.
 5. A protective garment asdefined in claim 1, wherein the outer shell further has a dynamic waterabsorption rating of less than about 15% after ten laundry cycles.
 6. Aprotective garment as defined in claim 1, wherein the outer shellfurther has a dynamic water absorption rating of less than about 10%after ten laundry cycles.
 7. A protective garment as defined in claim 1,wherein the outer shell further has a dynamic water absorption rating ofless than about 12% after twenty laundry cycles.
 8. A protective garmentas defined in claim 1, wherein said fabric has a rip stop weave.
 9. Aprotective garment as defined in claim 1, wherein said fabric has atwill weave.
 10. A protective garment as defined in claim 1, whereinsaid fabric has a plain weave.
 11. A protective garment as defined inclaim 1, wherein said fabric comprises fire resistant aramid fibers. 12.A protective garment as defined in claim 1, wherein said fabriccomprises fire-resistant polybenzimidazole fibers.
 13. A protectivegarment as defined in claim 1, wherein said fabric comprisesfire-resistant poly(p-phenylene-2,6-bezobisoxazole) fibers.
 14. Aprotective garment as defined in claim 1, wherein said fabric furthercomprises fire-resistant melamine fibers.
 15. A protective garment asdefined in claim 1, wherein the thermal barrier layer comprises a felt.16. A protective garment as defined in claim 1, wherein the durablewater resistant composition comprises a fluorocarbon polymer.
 17. Aprotective garment as defined in claim 16, wherein the durable waterresistant composition further comprises a polyisocyanate polymer.
 18. Aprotective garment as defined in claim 16, wherein the fluorocarbonpolymer comprises a perfluroalkyl polymer.
 19. A protective garmentsuitable for use by fire fighters, said protective garment comprising:an inner lining configured to cover a predetermined portion of awearer's body, the inner lining being positioned so as to be adjacentsaid wearer's body during use; an outer shell covering said innerlining, the outer shell comprising a woven fabric made from a fireresistant material, the woven fabric having a basis weight of at leastabout 5.5 ounces per square yard; and a durable water resistantcomposition incorporated into the woven fabric, the durable waterresistant composition being incorporated into the woven fabric such thatthe outer shell has a dynamic water absorption rating of no greater thanabout 7% after being laundered ten laundry cycles.
 20. A protectivegarment as defined in claim 19, wherein the outer shell has a basisweight of about 6 ounces per square yard or less.
 21. A protectivegarment as defined in claim 19, wherein the outer shell has a dynamicwater absorption rating of no greater than about 11% after twentylaundry cycles.
 22. A protective garment as defined in claim 19, whereinthe durable water resistant composition comprises a fluorocarbonpolymer.
 23. A protective garment as defined in claim 22, wherein thedurable water resistant composition further comprises a polyisocyanatepolymer.
 24. A protective garment as defined in claim 22, wherein thefluorocarbon polymer comprises a perfluroalkyl polymer.
 25. A protectivegarment as defined in claim 19, wherein the fabric comprises fibersselected from the group consisting of aramid fibers, polybenzimidazolefibers, poly(p-phenylene-2,6-bezobisoxazole) fibers, melamine fibers,and mixtures thereof.
 26. A protective garment suitable for use by firefighters, said protective garment comprising: an inner lining configuredto cover a predetermined portion of a wearer's body, the inner liningbeing positioned so as to be adjacent said wearer's body during use; anouter shell covering said inner lining, the outer shell comprising awoven fabric made from a fire resistant material, the woven fabrichaving a basis weight of at least about 5.5 ounces per square yard; anda durable water resistant composition incorporated into the wovenfabric, the durable water resistant composition being incorporated intothe woven fabric such that the outer shell has a water absorption ratingof no greater than about 2.5% after being laundered five laundry cycles.27. A protective garment as defined in claim 26, wherein the outer shellhas a basis weight of about 6 ounces per square yard or less.
 28. Aprotective garment as defined in claim 26, wherein the outer shellfurther has a dynamic water absorption rating of no greater than about7% after ten laundry cycles.
 29. A protective garment as defined inclaim 26, wherein the durable water resistant composition comprises afluorocarbon polymer.
 30. A protective garment as defined in claim 29,wherein the durable water resistant composition further comprises apolyisocyanate polymer.
 31. A protective garment as defined in claim 29,wherein the fluorocarbon polymer comprises a perfluroalkyl polymer. 32.A protective garment as defined in claim 26, wherein the fabriccomprises fibers selected from the group consisting of aramid fibers,polybenzimidazole fibers, poly (p-phenylene-2,6-bezobisoxazole) fibers,melamine fibers, and mixtures thereof.
 33. A protective garment suitablefor use by fire fighters, said protective garment comprising: an innerlining configured to cover a predetermined portion of a wearer's body,the inner lining being positioned so as to be adjacent the wearer's bodyduring use; an outer shell covering said inner lining, the outer shellcomprising a woven fabric made from a fire resistant material, the wovenfabric having a basis weight of at least about 5.5 ounces per squareyard; and a durable water resistant composition incorporated into thewoven fabric, the durable water resistant composition being incorporatedinto the woven fabric such that the outer shell has a dynamic waterabsorption rating of no greater than about 10% after being launderedfive laundry cycles and a dynamic water absorption rating of no greaterthan about 12% after being laundered twenty laundry cycles, the outershell also having a water absorption rating of less than about 2.5%after being laundered five laundry cycles.
 34. A protective garment asdefined in claim 33, wherein said fabric comprises fire resistant aramidfibers.
 35. A protective garment as defined in claim 33, wherein saidfabric comprises fire-resistant polybenzimidazole fibers.
 36. Aprotective garment as defined in claim 33, wherein said fabric comprisesfire-resistant poly(p-phenylene-2,6-bezobisoxazole) fibers.
 37. Aprotective garment as defined in claim 33, wherein said fabric furthercomprises fire-resistant melamine fibers.
 38. A protective garment asdefined in claim 33, wherein the durable water resistant compositioncomprises a fluorocarbon polymer.
 39. A protective garment as defined inclaim 38, wherein the durable water resistant composition furthercomprises a polyisocyanate polymer.
 40. A protective garment as definedin claim 39, wherein the fluorocarbon polymer comprises a perfluroalkylpolymer.
 41. A protective garment suitable for use by fire fighters,said protective garment comprising: an inner lining configured to covera predetermined portion of a wearer's body, the inner lining beingpositioned so as to be adjacent the wearer's body during use; an outershell covering said inner lining, the outer shell comprising a wovenfabric made from a fire resistant material, the woven fabric having abasis weight of at least about 5.5 ounces per square yard; and a durablewater resistant composition incorporated into the woven fabric, thedurable water resistant composition being incorporated into the wovenfabric such that the outer shell has a spray rating of 100% after beinglaundered thirty laundry cycles and pressed, has a water repellency ofat least about six after being laundered thirty laundry cycles and hasan oil repellency of at least about 5 after being laundered thirtylaundry cycles.
 42. A protective garment as defined in claim 41, whereinsaid fabric comprises fire resistant aramid fibers.
 43. A protectivegarment as defined in claim 41, wherein said fabric comprisesfire-resistant polybenzimidazole fibers.
 44. A protective garment asdefined in claim 41, wherein said fabric comprises fire-resistantpoly(p-phenylene-2,6-bezobisoxazole) fibers.
 45. A protective garment asdefined in claim 41, wherein said fabric further comprisesfire-resistant melamine fibers.
 46. A protective garment as defined inclaim 41, wherein the durable water resistant composition comprises afluorocarbon polymer.